Rebuilding a pumpkin... aka differential
 

I posted this in the Under the Hood section but I figured I would share it with others who might be interested in this project.

So I picked up a AP1 differential for cheap price knowing that it was probably blown (seller is a Honda mechanic and removed it from some kid's S2000 after he blew it). All he knew was that it would 'lock up' apparently. I figured the price was so low that it would be worth the investment and tackling on learning how to rebuild a differential and possibly throwing this one on my S2000. Worse case scenario is I would have a bunch of parts as paper weights and stuff to display in my office. :D

First thing is first... I try to drain it and found this stuck on the magnetic drain plug...

http://www.chillybanana.com/pictures...0-3034_IMG.jpg

Yikes... :o Not a good sign...

I pop off the output shafts...

http://www.chillybanana.com/pictures...0-3038_IMG.jpg

http://www.chillybanana.com/pictures...0-3036_IMG.jpg

I remove the differential case and clean up some of the oil...

http://www.chillybanana.com/pictures...0-3043_IMG.jpg

I start finding more metal chunks... not shavings or pieces... CHUNKS

http://www.chillybanana.com/pictures...0-3044_IMG.jpg

I can already see the pinon is heavily damaged...

http://www.chillybanana.com/pictures...0-3047_IMG.jpg

I proceed to mark the bearing caps and adjustment screws on both sides

http://www.chillybanana.com/pictures...0-3048_IMG.jpg

Not sure if this is a normal but one cap looks like it might have shifted...

http://www.chillybanana.com/pictures...0-3052_IMG.jpg

One of the lock plates looks like it has shifted too...

http://www.chillybanana.com/pictures...0-3053_IMG.jpg

Bearing caps off...

http://www.chillybanana.com/pictures...0-3055_IMG.jpg

More chunks from the pinon...

http://www.chillybanana.com/pictures...0-3058_IMG.jpg

http://www.chillybanana.com/pictures...0-3060_IMG.jpg

LSD + ring gear...

http://www.chillybanana.com/pictures...0-3064_IMG.jpg

Using an impact gun, I removed the locknut

http://www.chillybanana.com/pictures...0-3062_IMG.jpg

The companion flange popped off using a puller

http://www.chillybanana.com/pictures...0-3065_IMG.jpg

Drive pinon out...

http://www.chillybanana.com/pictures...0-3068_IMG.jpg

More chunks...

http://www.chillybanana.com/pictures...0-3071_IMG.jpg

Pinon totally trashed...

http://www.chillybanana.com/pictures...0-3073_IMG.jpg

http://www.chillybanana.com/pictures...0-3074_IMG.jpg

Ring gear damaged

http://www.chillybanana.com/pictures...0-3075_IMG.jpg

I had to stop to BBQ for dinner but this will be a part time project... :p If it's salvageable, I might plan on getting a Kia 4.77 gear + pinon... :) I'll have to replace various seals, spacer, clips, washers anyhow... I'm reaching out to the S2Ki.com community for their thought and input... more updates as I make more progress...

*****Update*****

Bought $150 in parts to replace the oil seals, bearings, cups, nut and pinion spacer.

http://www.chillybanana.com/pictures...0-4313_IMG.jpg

New axle oil seals
http://www.chillybanana.com/pictures...0-3077_IMG.jpg

Used a socket + mallet to press into place:
http://www.chillybanana.com/pictures...0-3079_IMG.jpg

Finished product
http://www.chillybanana.com/pictures...0-3080_IMG.jpg

Baffle back into place with some lock tight

I wouldnt try to do that myself, its cool you are doing it urself!

damn , that thing blew up

what a project!

very cool, and nice pictures! i'm learning just from this thread! thanks!!

wow that looks like alot of work, i would not know how to take those things apart

whats with the kia parts?

[QUOTE=turbomagazine.com]Honda sourced the Mazda 7-inch rear for the Honda S2000. This doesn't necessarily mean you can simply bolt a Mazda rear end on your S2K and call it a day because of the difference in rear housing and axel designs. It seems Mazda has been sourcing out its gears to Honda S2Ks and '94-'02 Kia Sportages 4x4. The front axle of the Sportage has a Mazda 4.778 ring and pinion (part number MM05727110), which high-performance retailers have been secretly selling as an aftermarket gear for over $1,000. The only difference between the $1,000 unit and the $267.93 gear set we bought is, of course, the price gouging and the possibility of a few retailers who add cryogenic treatment to the units as a bonus. The same 4.77 final gear set found in the Kia is interchangeable to fit on the S2K as a direct bolt on, as well as the Mazda final drive off a stock RX-8 with a 4.44 ratio. Upon further research, we found numerous final drive setups that were all interchangeable between the S2K and Mazda, including a n/a powered S2K's dream come true 4.625 ratio, which is available on the New Zealand Kia Sportage. When comparing the S2K factory 4.1-ratio final drive to the 4.77 final installed in our factory pumpkin, we found numerous pros and cons attributed with this setup.

Vehicle Year/Model

Same exact thing happened to me

http://i130.photobucket.com/albums/p...r/IMG_1618.jpg

http://i130.photobucket.com/albums/p...r/IMG_1625.jpg
Not a good sign :(

http://i130.photobucket.com/albums/p...r/IMG_1620.jpg

http://i130.photobucket.com/albums/p...r/IMG_1624.jpg

http://i130.photobucket.com/albums/p...r/IMG_1623.jpg

http://i130.photobucket.com/albums/p...r/IMG_1621.jpg
Now thats a souvenir!

i'm too chicken to tackle a job like that, kudos to you